Building structure



Jan. 19, 1943. l. sTAGG BUILDING STRUCTURE Fi1ed Feb. 12, 1940 2 sheets-sheet 1 FIGJ.

FIG.7.

INVENTOR. |Rv|NG STAGG BY A 2 1 VA TTORNEYS Jan. 19, 1943'. l. sTAGG BUILDING STRUCTURE 2 Sheets-Sheet 2 Filed Feb. l2, 1940- f IJ lllllllll lu INVENTOR. IRVING STAGG BY ATTORNE .1

FIGJT..

ratentea Jan. w, 1345 UNITED STATES PATENT OFFICE BUILDING STRUCTURE Irving Stagg, Garden City, Mich. Application February 12, 1940, Serial No. 318,615

(Cl. 'l2-35) 9 Claims.

This invention relates generally to building materials and structures and refers more particularly to structural building blocks adapted for use in the walls of buildings.

One of the essential objects of the invention is to eiect a material saving in the cost of constructing buildings of various types, especially small homes for wage earners having relatively low incomes. 1

Another object is to provide a block structure capable of producing on the outer side of a wall of a building a Wood siding or shingle effect.

Another object is to provide a block structure that alleviates the necessity for woodwork upon either the outer or inner sides of outer walls formed by such blocks. Thus, a substantial saving in labor and materials has been eiected.

Another object is to provide a block structure wherein provision is made for draining off to the exterior of the wall any moisture caused by condensation of cold air between the body and louter facing of the block.

Another object is to provide a block structure wherein Waterproofing material in sheet form is utilized between the body and outer facing of the block to prevent water from entering or seeping into the pores of the body and to cooperate with the facing to facilitate the drainage mentioned. 'Ihis waterproofing material also serves as an insulator against cold, heat, moisture, etc.

Another object is to provide a block structure wherein provision is made for effectively sealing the joints between adjacent blocks against moisture and the weather elements generally. In this connection the waterproofing material mentioned is utilized to overlap the joints between the blocks.

Another object is to provide a block structure wherein provision is made for producing a neat and smooth exterior joint between adjacent blocks.

Another object is to provide a block structure wherein provision is made for effectively bonding together adjacent blocks.

Another object is to provide a block structure that may be made from any suitable plastic material.

Another object is to provide a block structure which eliminates in wall constructions the need for grounds or furring strips, lathing and the like. A wall formed from blocks embodying my invention requires only a finish coating of plaster. The brown or scratch coatings heretofore necessary when plastering walls of conventional or previous designs are unnecessary and may be dispensed with entirely.

Another object is to provide a block structure that may be assembled or laid by unskilled labor without troweling. Due tothe construction of the blocks embodying my invention it is possible to lay or assemble three or four blocks one above the other before applying any bonding agent or material thereto.

Another object is to provide a block structure that permits bonding material such as a light cement grout to be applied after several blocks are laid or assembled on top of one another.

Another object is to provide a block structure wherein a firm union between adjacent .blocks is insured notwithstanding a light cement grout is applied after several blocks have been laid or assembled as aforesaid.

Another object is to provide a block structure that precludes wastage of mortar or bonding agent both inside and outside the wall built from said blocks.

Another object is to provide a block structure having passages therein for air and arranged in such a way relative to the spaces for bonding agents that none of the later can get into such air spaces to clog or obstruct the same.

Another object is to provide a block structure that effects a material saving in time for the construction of a wall. With my structure it' is possible to proceed with the nish plaster coating immediately after the wall is erected. Under prevailing methods of construction the plasterer must wait until the carpenter prepares the wall for the lather, and the finish coating of plaster cannot be applied until after the brown or scratch coating has been applied and has had time to dry.

Another object is to provide a block structure which produces a seamless appearance upon the outer face of the wall.

Another object is to provide a block struc- Another object is to provide a block structure that may be used in such a way with windowl frames that the usual stone sills may be dispensed with entirely.

Another object is to yprovide a block structure that permits stucco to be applied thereto by a spraying operation. Thus, troweling is unnecessary.

Another object is to provide a block structure which permits the bonding agent to be applied .by either hydraulic pressure or by mechanical pressure or by any other suitable pressure. l

Another object is to provide a block structure that may be made by a vibrating process in connection with a suitable conveyer.

Other objects, advantages and novel details of construction of this invention will be made more apparent as this description proceeds, especially when considered in connection with the accompanying drawings, wherein:

Figure 1 is a fragmentary elevation of a wall formed of blocks embodying my invention and showing a portion' of a window frame structure in combination therewith;

Figure 2 is a fragmentary vertical sectional View through a wall structure having therein blocks embodying my invention;

Figure 3 is a horizontal sectional View taken substantially on the line 3-3 of Figure 1;

Figure 4 is a bottom lplan view of one of the blocks;

Figure 5 is a vertical sectional view through superposed blocks of the type illustrated in Figure 4;

Figure 6 is an elevation of the inner side of the o face plate of one of the blocks illustrated in Figure 5;

Figure 7 is a top plan view of the face plate illustrated in Figure 6;

Figure 8 is a sectional view taken on the line 8-8 of Figure 6;

Figure 9 is a sectional view taken on the line 9-9 of Figure 6;

Figure 10 is a top plan view of a corner of a Wall structure having therein blocks embodying my invention;

Figure 11 is a bottom plan View of one of the blocks illustrated in Figure 10;

Figure 12 is a horizontal sectional view through the block shown in Figure 3;

Figure 13 is a bottom plan view of the block shown in Figure 12, with the face plate and water-proofing material in section;

Figure 14 is a sectional view taken on the line I4-I4 of Figure 13;

Figure 15 is a horizontal sectional View through the meeting ends of the body portions of adjacent blocks embodying my invention;

Figure 16 is a horizontal sectional view through the face plates and waterproofing material and lportions of adjacent blocks embodying my invention;

Figure 17 is a horizontal sectional view through face plates and insulating material at a corner of a wall formed by blocks embodying my invention.

Referring now to the drawings, A is the body portion, B is the face plate, and C is the water- -proong material of a block structure embodying my invention. Y

As shown, the body portion A is a casting formed from plastic material. Preferably this body portion is formed in a suitable mold (not shown) and comprises a mass of cinders and cement. In the present instance, the body portion A is substantially rectangular-shape in configuration and is solid except for two vertically extending openings I0 and II of square cross section at spaced points longitudinally thereof, and an intermediate opening I2 of circular cross section. The inner face I3 of the body portion A is flat and substantially vertical, while the outer face I4 is flat and inclines downwardly and outwardly. In opposite ends of the body portion A, preferably at the longitudinal median line thereof, are outwardly opening vertical slots I5 of semi-circular cross section. By referring to Figure 15, it will be noted that these slots are slightly offset inwardly relative to the vertical side edges I6 of the block and that the intermediate faces I'I and I8 are flat and incline outwardly from opposite side edges of the slots to the side edges I6 of the block. The top and bottom faces I 8 and I9 of the body portion A are substantially parallel and are disposed at substantially right angles to the inner face I3 of the body portion. The #top 'face I8' is substantially flat, while the bottom face I9 is provided about the edges of the openings I0 and II and -along the longitudinal side edges of the body portion A with relatively shallow depending ribs or flanges 20 and 2 I.

'I'he face plate B is also a casting formedfrom plastic material in a suitable mold (not shown). Preferably this face plate has an area greater in a downward direction than the area of the outer face I 4 of the body portion A so as to extend' slightly .below the lower edge of said body portion for overlapping engagement with the upper edge of a face plate of a lower block in a wall formation. As shown, this face plate is a relatively thin slab-like member secured in face-toface relation by metal straps 22 to the body portion A. Such straps are terminally embedded in the body portion and face plate and are preferably substantially T-shape in plan. If desired, the entire strap or the stem portion thereof may be corrugated to insure a proper anchorage and union between the parts. The outer face 23 of the face plate is at and smooth, while the inner face 24 is flat but has crossed diagonally extending grooves 25 therein. In this connection it will be noted that the upper ends of the grooves 25 are spaced slightly below the upper edge of the plate, while the lower ends of the grooves open downwardly through the lower edge of the face plate. To permit the joints .between adjacent body portions A of the blocks to be sealed and to provide a smooth exterior surface when the blocks are assembled in a wall formation, opposite ends 26 of the face plates are beveled inwardly from the outer to the inner surfaces of said plates.

Thewaterproong material C is preferably in sheet form and is located in surface-to-surface relation with the body portion A and face plate B. Preferably this waterproofing material has a greater length than the body portion A and face plate B to provide marginal endwise extensions 21 for overlapping the joints between adjacent blocks whenassembled in a Wall formation.

The blocks described above are intended for use in wall formations except at the corners thereof and at the window or door openings therein. At the corners the blocks are formed as illustrated in Figures 10, 11 and 17, respectively. As shown, the body portion A of the corner block is provided at its outer end with a face plate B and waterproofing material C', as on its outer face, and is provided in its inner face with a vertically extending groove 28 of semi-circular cross section for registration with the semi-circular groove I5 in the end of the adjacent intermediate block. In this corner construction the adjacent ends 29 and 3E; of the face plates B and F B are flat and extend at right angles to the sides of the plates, and the waterproofing material C and C has overlapping extensions 21 and 21. Other than this, the block structure at the corners of the wall is like that previously described.

At window and door openings in the wall the body portion A2 of each block is provided in its outer face at one end with a -groove 3| for receiving the blind stop 32 of the window frame structure. Both the face plate B2 and waterproofing material C2 terminate short of the adjacent end 33 of the body portion A2 so as to overlap the groove 3l and abut the otside casing 34 of the window frame structure. As shown, the face plate B2 and waterproofing material C2 overlap the outer face of the blind stop 32. The end 33 of the body portion A2 is flat for surfaceto-surface engagement with the jamb 35 of the window frame and is provided with a vertical groove 36 of semi-circular cross section that is opposite a suitable vertical groove 31 in the jamb 35. The inner corner 38 of the body portion A2 is preferably rounded so as to curve from the adjacent edge 39 of the jamb to the inner face 40 of the body portion. Opposite ends of the sill 50 of the window frame are recessed to receive the adjacent blocks 42 of the Wall structure.

epending upon the arrangement of blocks in the wall formation, the window or door blocks such as that just described may be half size as illustrated in Figures 3, 12 and 13 and thus have only one vertical opening 4| of square cross section, or may be full size as at 42 (Figure 1). Otherwise, they are like the blocks illustrated in Figures 4 and 5. When assembled in a wall formation as illustrated in Figures 1 and 2, the blocks are arranged in staggered, superposed relation upon a foundation. Preferably the lower part 53 of this foundation, i. e., the part below the ground level 53', comprises rectangular blocks devoid of face plates and waterproofing material, while the upper part 54 is composite in construction and preferably comprises an outer section 55 of regular bricks and an inner section 56 of blocks such as those used in the lower part 53 of the foundation.

The lowermost row X of blocks are laid on the foundation beyond the ends of joists or beam such as 60 so that the face plates B overhang the outer face of the brick 55. The next and succeeding rows of blocks are laid with their face plates B overhanging the face plates of the adjacent lower blocks and with the square openings I and Il in vertical alignment. Thus, a Wood siding effect is produced, and moisture caused by condensation of air coming in from the outside to the waterproofing material C will drain down the grooves in the face plates to the exterior of the wall structure. Moreover, the valigned square openings I0 and Il provide vertical air ducts in the wall formation, as illustrated in Figure 5, for insulating and other advantageous purposes.

When several rows of blocks are laid, a suitable bonding material may be forced by a hydraulic or mechanical gun or by any other pressure means (not shown) into the circular holes l2 and into the opposed semi-circular holes I5 and 28. Such bonding material will flow into and fill the spaces 1B (Figure 5) between the depending ribs 20 and 2l and the upper face of the lower blocks, and will ll the spaces 1I (Figure 15) provided by the inclined faces I1 and i8 at the ends of the blocks. Such bonding material is also placed in the spaces 12 (Figure 16) provided by the beveled ends of the face plates B to cooperate with the overlapping end portions 21 of the waterproofing material to seal the joints between adjacent blocks. This bonding material also lls the grooves 31 and 36, respectively, in the window frame and adjacent blocks. Thus, a Weather-tight wall is provided. The inner face of the wall so formed is smooth and may be provided with a finish coating (not shown) of plaster as soon as erected.

In the process of construction the face plate B provided with the straps 22 is preferably formed first in a suitable mold. This plate with the waterproofing material C applied thereto is then placed into a suitable mold where the body portion A is formed. Any suitable plastic material may be used in the formation of the body portion A and face plate B, and likewise any suitable waterproong material C in sheet form may be employed.

What I claim as my invention is:

1. A wall structure having block-like castings wider at the bottom than at the top thereof aigranged one on top of the other withthe bottom of t'le-'p'perrnost-casting projecting outwardly beyond the narrower top of the next lower casting, the outer faces of said castings inclining downwardly and outwardly from the top to the bottom thereof, slab-like face plates covering in surface-to-surface relation the outer inclined faces of the castings, the face plate on the uppermost casting extending downwardly below the bottom of the uppermost casting and overlapping the outer face of the face plate on the next lower casting, the inner surface of the face plate on the uppermost casting having drainage grooves therein for moisture,extendingdwnwdlywfrmwpiitsjacent the upper edge of said face plate over the outer surface of the face plate on the next lower casting, and means securing the face plates to said castings.

2. A wall structure having block-like castings wider at the bottom than at the top thereof arranged one on top of the other with the bottom of the uppermost casting projecting outwardly beyond the narrower top of the next lower casting, the outer faces of said castings inclining downwardly and outwardly from the top to the -bottom thereof, imperforate sheets of waterproofing material covering in surface-to-surface relation the inclined outer faces of said castings, slab-like face plates covering in surface-to-surface relation the imperforate sheets of waterproofing material, the face plate and the waterproofing material on the uppermost casting extending downwardly below the bottom of the uppermostfcasting and overlapping the outer surface of the face plate on the next lower casting, the inner surface of the face plate on the uppermost casting having drainage grooves therein for moisture extending downwardly from points adjacent the upper edge of said face plate over the outer surface of the face plate on the next lower casting, and means securing the face plates and waterproofing material to said castings.

3. A wall structure having block-like castings wider at the bottom than at the top thereof arranged one on top of the other with the bottom of the uppermost casting projecting outwardly beyond the narrower top of the next lower casting, the outer faces of said castings inclining downwardly and outwardly from the top to the bottom thereof, imperforate sheets of waterproofing material covering in surface-to-surface relation the inclined outer faces of said castings, slab-like face plates covering in surface-to-sur- "'face relation the imperforate sheets of waterproofing material, a space for the drainage downward of moisture being provided between the waterproofing material and face plates, both the face plate and waterproofing material on the uppermost casting extending downwardly below the bottom of the uppermost casting and overlapping the outer surface of the face plate on the next lower casting, whereby moisture draining downwardly in the space between the waterproofing material and face plate on the uppermost casting will flow over the outer face of the face plate on the next lower casting, and means securing the face plates and waterproofing material to said castings.

4. A wall structure having structural blocks arranged end-to-end, each having a body prtion and a face plate, opposed ends of the face' plates meeting over the joints between adjacent blocks and being beveled inwardly from the outer to the inner faces of said plates so as to provide substantially V-shaped recesses straddling and opening toward the joints between the blocks for the reception of sealing material, imperforate sheets of waterproofing material between and in surface-to-surface relation to the body portions and face plates of the blocks, adjacent ends of the waterproofing material overlapping each other within said V-shaped recesses over the joints between the blocks, sealing material in said V-shaped recesses and holding the overlapping ends of the waterproofing material in place over said joints, and means securing the face' plates and waterproofing material to the body portions of the blocks.

5. In a wall structure, a block-like casting wider at the bottom than at the top thereof whereby one face of the casting inclines downwardly and outwardly from the top to the bottom thereof, a slab-like face plate covering in surface-to-surface relation the inclined face aforesaid of the casting and extending downwardly below the bottom of the casting so as to overlap the outer face of a face plate on another casting immediately below the casting aforesaid, the inner surface of the first mentioned face plate having crossed diagonally arranged drainage grooves therein for moisture extending downwardly from points adjacent the upper edge of said first mentioned face plate below the bottom of the casting so as to overlie the outer face of the second mentioned face plate, and means securing the rst mentioned face plate to said rst mentioned casting.

6. A wall structure having structural blocks wider at the bottom than at the top thereof arranged one on top of the other with the bottom of the uppermost block projecting outwardlyA beyond the narrower top of the next lower block, the outer faces of said blocks inclining downwardly and outwardly from the top to the bottom thereof, separate preformed slab-like face plates covering in surface-to-surface relation the outer inclined faces of the blocks, a space for the drainage downward of moisture being provided between vthe inclined outer faces of the blocks and the face plates, the face plate on the uppermost block extending downwardly below the bottom of the uppermost block and overlapping the outer face of the face plate on the next lower block, whereby moisture draining downwardly in the space between the inclined outer face of the uppermost block and the face plate thereon will flow over the outer face of l the face plate on the next'lower block. and means securing the face plates to said blocks.

7. In a wall structure, a structural building block comprising a block-like casting wider at the bottom than at the top whereof whereby one face of the casting inclines downwardly and outwardly from the top to the bottom thereof, a separate slab-like face plate substantially equal in area to and disposed in surface-to-surface relation upon said inclined face, an imperforate sheet of waterproofing material substantially equal in area to and disposed in surfaceto-surface relation between the face plate and the inclined face of the casting, the inner surface of the face plate having crossed drainage grooves therein for moisture extending downwardly from points adjacent the upper edge of said face plate to the lower edge thereof and cooperating with the outer surface of the sheet of waterproofing material to form downwardly extending drainage 'passages upon but separate from "the inclined face of the casting, and means securingy the face plate and waterproofing material to said casting.

8. A wall structure having block-like castings arranged one against the other in a common horizontal plane, face plates for said blocks having their adjacent ends meeting over the joint between said castings and being beveled inwardly from their outer to their inner faces so as to provide a substantially V-shaped recess straddling and opening toward the joint between the blocks for the reception of sealing material, imperforate sheets of waterproofing material between and in surface-to-surface relation to the castings and face plates, adjacent ends of the waterproofing material overlapping each other within said V-shaped recess over the joint be- "tween the blocks, sealing material in said V- shaped recess and holding the overlapping ends of the vwaterproofing material in place over said joint, and means securing the face plates and waterproofing material to said castings.

9. A wall structure having structural blocks wider at the bottom than at the top thereof arranged one on top of the other with the bottom of the uppermost block projecting outwardly beyond the narrower top of the next lower block,

the outer faces of said blocks inclining downwardly and outwardly from the top to the bottom thereof, imperforate sheets of waterproofing material covering in surface to surface relation the inclined outer faces of said blocks, slab-like face plates covering in surface to surface relation the imperforate sheets of waterproofing material, the face plate and the waterproofing material on the uppermost block extending downwardly below the bottom of the uppermost block and overlapping the outer surface of the face plate on the next lower block, the inner surface of theface plate on the uppermost block havingdrainage grooves therein for moisture cooperating with the outer surface of the waterproofing material on the uppermost block to form drainage passages, said drainage passages extending downwardly from points adjacent the upper edge of the face plate on the uppermost block to the lower edge of said face plate and opening onto the outer surface of the face plate on the next lower block, and means securing the face plates and waterproofing material to said blocks.

IRVING STAGG. 

